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United States Patent |
6,105,895
|
Schmodde
,   et al.
|
August 22, 2000
|
Yarn tension sensor with improved calibration
Abstract
A yarn feeder intended particularly for flatbed knitting machines and
elastic yarns has a yarn tension sensor which is provided with a
calibration device. This device lifts the yarn from a peg that is part of
the yarn tension sensor, at times in which this can be done without
impairing operation of the yarn feeder. Such times are preferably time
slots when no yarn feeding is necessary. Once the yarn has been lifted
from the peg, a zero point calibration is performed. Zero point drifting
of the entire sensor system, including its measurement circuit, can be
detected and compensated for.
Inventors:
|
Schmodde; Hermann (Horb-Dettlingen, DE);
Leins; Eberhard (Horb, DE);
Weber; Friedrich (Herzogsweiler, DE)
|
Assignee:
|
Memminger-IRO GmbH (Dornstetten, DE)
|
Appl. No.:
|
268854 |
Filed:
|
March 15, 1999 |
Foreign Application Priority Data
| Mar 14, 1998[DE] | 198 11 241 |
Current U.S. Class: |
242/420.6; 226/45; 242/418.1 |
Intern'l Class: |
B65H 023/06; B65H 059/02; B65H 077/00; B65H 023/18; B65H 059/18 |
Field of Search: |
242/418.1,420.6,421.7
73/862.39,1.08
226/45
|
References Cited
U.S. Patent Documents
3578795 | May., 1971 | Polese.
| |
3807612 | Apr., 1974 | Eggert | 242/418.
|
3858416 | Jan., 1975 | White et al.
| |
4347993 | Sep., 1982 | Leonard.
| |
Foreign Patent Documents |
0 305 811 A2 | Mar., 1989 | EP.
| |
0 406 735 A2 | Jan., 1991 | EP.
| |
39 42 341 | Jun., 1991 | DE.
| |
193 37 215 | Apr., 1997 | DE.
| |
195 37 215 A1 | Apr., 1997 | DE.
| |
359128168 | Jul., 1984 | JP.
| |
8301497 | Nov., 1984 | NL.
| |
2 015 589 A | Sep., 1979 | GB.
| |
WO 97/13131 | Apr., 1997 | WO.
| |
Primary Examiner: Walsh; Donald P.
Assistant Examiner: Webb; Collin A.
Attorney, Agent or Firm: Frishauf, Holtz, Goodman, Langer & Chick, P.C.
Claims
What is claimed is:
1. A yarn tension sensor (1) for detecting the tension of a moving yarn
(7), comprising:
a yarn feeler element (21), which is disposed in a yarn travel path and has
a bearing face for the yarn (7),
a measuring device (5), connected to the yarn feeler element (21), for
detecting the force exerted by the yarn (7) on the yarn feeler element
(21), and
an actuator device (48), by means of which the yarn feeler element (21) and
the yarn (41) are movable relative to one another between a calibration
position and a measurement position in such a way that in the calibration
position, the yarn does not rest on the yarn feeler element (21), and in
the measurement position, the yarn does rest on the yarn feeler element
(21).
2. The yarn tension sensor of claim 1, characterized in that the direction
of motion defined by the actuator device (48) is defined crosswise to the
yarn.
3. The yarn tension sensor of claim 1, further comprising a yarn takeup
system (41), and characterized in that the yarn takeup system (41) and the
yarn feeler element (21) are disposed on the same, defined side of the
yarn, and that the yarn takeup system (41) in the calibration position
lifts the yarn from the yarn feeler element (21) and in the measurement
position does not rest on the yarn, but the yarn rests on the yarn feeler
element (21).
4. The yarn tension sensor of claim 1, further comprising a yarn takeup
system (41), and characterized in that the yarn takeup system (41) and a
slit (21), in which the yarn feeler is disposed, are disposed on defined,
opposed sides of the yarn, and that in the calibration position, the yarn
takeup system (41) causes the yarn to be lifted from the yarn feeler
element (21) and, in the measurement position, it keeps the yarn in
contact with the yarn feeler element (21).
5. The yarn tension sensor of claim 1, further comprising a yarn takeup
system (41), and characterized in that the actuator device (48) is
connected to the yarn takeup system (41) in order to move the yarn takeup
system out of the calibration position into the measurement position and
back, and that the yarn feeler element (21) is disposed substantially,
that is, except for its measurement travel, in stationary fashion.
6. The yarn tension sensor of claim 5, characterized in that the actuator
device (48) is an electric linear drive mechanism (49, 51, 56).
7. The yarn tension sensor of claim 1, characterized in that the actuator
device (48) is an electric linear drive mechanism (49, 51, 56).
8. The yarn tension sensor of claim 1, further comprising a yarn takeup
system (41), and characterized in that the yarn takeup system (41) is
formed by at least one yarn receiver (42, 43), which is disposed adjacent
to the yarn feeler element (21).
9. The yarn tension sensor of claim 1, characterized in that the yarn
feeler element (21) is supported movably and substantially crosswise to
the yarn travel path, and the measuring device (5) includes a travel
pickup system (38, 39).
10. The yarn tension sensor of claim 9, characterized in that the travel
pickup system (38, 39) has two travel pickups, which are connected to a
measurement circuit (61), which includes a subtractor (65) to whose inputs
(+, -) the travel pickups of the measuring device (5) are connected.
11. The yarn tension sensor of claim 1, characterized in that the yarn
feeler element (21) is supported by means of a spring parallelogram (28,
29) on a base (35) that also supports a travel pickup system (38, 39) and
is supported (36) resiliently and/or in damped fashion.
12. The yarn tension sensor of claim 1, characterized in that the yarn
feeler element (21) is a peg disposed crosswise to the direction of motion
of the yarn (7), and the yarn (7) is unguided with respect to the
longitudinal direction of the peg.
13. The yarn tension sensor of claim 1, further comprising a yarn takeup
system (41), and characterized in that the yarn takeup system (41) is part
of a calibration device (40), which is intended for setting a reference
value for the measuring device (5).
14. The yarn tension sensor of claim 13, characterized in that the
calibration device (40) is activatable by a signal, output by the machine,
that defines a state in which the yarn (7) has a speed which is less than
a predetermined limit value.
15. The yarn tension sensor of claim 14, characterized in that the limit
value of the yarn speed is zero.
16. The yarn tension sensor of claim 1, characterized in that a regulating
device for keeping the yarn tension constant is connected to the measuring
circuit (61), and that the regulating device has an inactivation input,
and the regulating device does not change its output signal when a
corresponding signal has arrived at the inactivation input.
17. A yarn feeder for knitting machines with highly fluctuating yarn
consumption, comprising:
a yarn feed wheel (4) driven by an electric motor,
a regulating device for triggering the electric motor (4) such that the
requisite yarn quantity is supplied and the yarn tension is kept within
predeterminable limits,
the yarn tension sensor (5) of claim 1, and
a calibration device (40) for the yarn tension sensor (5) which is
activated by a calibration pulse and by which the yarn takeup system (21)
and the yarn tension sensor can be moved to the calibration position with
respect to one another for calibration of the yarn tension sensor (5).
18. The yarn feeder of claim 17, characterized in that the yarn feed wheel
(4) has a pivot axis (22), which is disposed in the direction that is
normal to a plane (24) with which the outgoing yarn (7) forms an acute
angle.
19. The yarn feeder of claim 18, characterized in that the calibration
device (40) is activatable upon a change of direction of the yarn guide of
a flatbed knitting machine or in a change of yarn in stocking and sock
knitting machines, or in other pauses in yarn consumption by machines.
20. The yarn feeder of claim 18, characterized in that the calibration
device (40) is controlled by the yarn speed.
21. The yarn feeder of claim 20, characterized in that the calibration
device (40) is inactive at least whenever the yarn speed exceeds a limit
value.
22. A method for calibrating a yarn tension sensor comprising the steps of:
detecting a signal that defines a state in which the yarn tension is
allowed to deviate briefly from its set-point value,
separating a yarn from the yarn tension sensor,
detecting the signal output by the yarn tension sensor once the yarn has
lifted, and
placing the yarn on the yarn tension sensor again.
23. The method of claim 22, characterized in that the signal defines a yarn
speed that is less than a predetermined limit value.
24. The method of claim 22, characterized in that the measured value
detected with the yarn lifted is taken as the zero value.
25. The method of claim 22, characterized in that the calibration operation
in a flatbed knitting machine is performed at the reversal of direction
and/or upon starting.
26. The method of claim 22, characterized in that the calibration operation
is performed with the yarn in motion within a time slot in which the yarn
speed is constant.
Description
FIELD OF THE INVENTION
The invention relates to a yarn tension sensor, in particular for feeding
elastic yarns to knitting machines, to a yarn feeder for knitting
machines, and to a method for calibrating a yarn tension sensor.
BACKGROUND OF THE INVENTION
In many industrial textile applications, especially in knitting machines,
it is often necessary to keep yarns which are to be furnished to knitting
stations or other locations at a constant tension. This is especially
important in flatbed knitting machines, which because of the reciprocating
motion of the yarn guide (carriage) have a yarn consumption that
fluctuates very greatly over time. A corresponding yarn feeder must then
furnish the yarn at a speed that repeatedly varies abruptly over time. If
the yarn tension changes, for instance during, before or after the
reversal of motion of the yarn guide, then the mesh size of the knitted
product changes, which impairs its appearance, elasticity, and quality. In
this respect, the edge regions of knitted goods made on flatbed knitting
machines are especially critical.
Special demands must be made of the constancy of tension when elastic yarns
(e.g. Spandex.TM.) are supplied, which are for instance knitted jointly
with other yarns. To keep the yarn tension constant, it is necessary to
monitor the tension constantly and to regulate the yarn feed quantity
accordingly.
To that end, a yarn feeder for elastic yarns is known, for instance from
German Patent Disclosure DE 195 37 215 A1, that is intended for use in
flatbed knitting machines. The yarn feeder is used to feed Spandex.TM.
yarns and has a yarn feed wheel driven by an electric motor. The electric
motor is triggered by a closed control loop that detects the current yarn
tension with a yarn tension sensor. The yarn tension sensor has a peg that
can be deflected crosswise to the yarn travel direction, and the yarn is
guided over this peg at an obtuse angle. The peg deflection corresponds to
the yarn tension and is detected by a suitable travel sensor.
A yarn feeder for knitting machines is also known from U.S. Pat. No.
3,858,416; it likewise has a yarn feed wheel which is driven by a motor.
The motor is triggered by a closed control loop that detects the yarn
tension with a yarn tension sensor. The yarn tension sensor has a
deflectable peg over which the yarn travels.
From German Patent Disclosure DE 39 42 341 A1, a force sensor for
monitoring yarn tensions is known in which a sensor element is supported
on a spring parallelogram. The deflection of the sensor element is
transmitted to a bending body that is provided with variable resistance,
so that the deflection of the sensor element and thus the yarn tension can
be detected electrically.
The constancy of tension is of major importance especially when elastic
yarns for making elastic knitted goods are being supplied. Even minimal
fluctuations, and especially longer-lasting changes, lead to changes or
variations in quality. It is therefore important that the yarn tension be
kept stable over long periods of time, that is, over the course of hours,
days and months.
Knitting machines and yarn feeders are often used in large factory spaces
in which the temperature varies, both over the course of the day and
depending on how long the machines have been running, and not least
because of the heat loss from the knitting machines. Thus the temperatures
of the yarn tension sensors vary as well, which despite temperature
compensation means that may be present can have an effect on their output
signal. Persistent dirt deposits can also lead to a change in the sensor
output signal, for instance if deposits on a peg for detecting the yarn
tension increase the total weight of the peg and thus shift the zero point
of the signal.
SUMMARY OF THE INVENTION
It is an object of the invention to create a yarn tension sensor which
enables stable detection of the yarn tension over long periods of time.
Another object of the invention is to provide a yarn feeder that supplies
the yarn at a constant yarn tension, for instance in a flatbed knitting
machine.
It is a further object of the invention to provide a method for operating a
yarn tension sensor in the employment of which the sensor outputs a
reliable output signal that is stable over long periods of time.
These and other objects are attained in accordance with one aspect of the
invention which is directed to a yarn tension sensor that, in addition to
its yarn feeler element, which is used to measure the yarn tension by
being in contact with the yarn, the yarn tension sensor has a yarn takeup
system that is movably supported. It has at least two different positions,
which differ in that in a calibration position, the yarn is separated from
the yarn feeler element and in the measurement position of the yarn takeup
system, the yarn rests on the yarn feeler element. Thus, by adjusting the
yarn takeup system and/or the yarn tension sensor, it is possible to lift
the yarn arbitrarily from the yarn feeler element so that the yarn feeler
element assumes its position of rest. This position is defined in that no
force is acting on the yarn feeler element. The measuring device detects
this position or this state of the yarn feeler element. If drift has
occurred in the mechanical or electrical system of the yarn tension
sensor, this can be recognized and detected when the yarn lifts from the
yarn feeler element. For instance, the lifting of the yarn from the yarn
feeler element can be used for the zero calibration of the yarn tension
sensor. In this way, even long-term offsets can be averted which would
otherwise be superimposed on the output signal of the yarn tension sensor.
With the recognition and exclusion of offset factors that could for
instance be caused by temperature drifting or by deposits on the yarn
feeler element, a sensor output signal is generated over the long term
that reproduces the yarn tension in a manner free of zero point errors.
This makes it possible to construct a yarn feeder with high long-term
constancy of the yarn tension.
This is achieved by repeatedly calibrating the yarn tension sensor over the
course of yarn feeder operation, and particularly by repeatedly performing
a zero point calibration. This is attained by lifting and/or moving the
yarn away from the yarn tension sensor and detecting the measured value
with the yarn lifted away. The measured value detected is the zero point
for the yarn tension detected by the yarn tension sensor after the yarn
has been placed back on the yarn feeler element.
In a first embodiment, the yarn feeler element and the yarn takeup system
are disposed on opposite sides of the yarn travel. For measuring, the yarn
takeup system "presses" the yarn against the yarn feeler element. For
calibration, it causes the yarn to lift away from the yarn feeler element.
In a second embodiment, the yarn feeler element and the yarn takeup system
are disposed on the same side of the yarn travel. For calibration, the
yarn takeup system "presses" the yarn away from the yarn feeler element.
For measurement, it causes the yarn to rest on the yarn feeler element.
In both embodiments, the sensor can be moved in a first design, while in a
second design the yarn feeler element is movably supported.
The calibration or zero point calibration operation is preferably performed
whenever the yarn feeder is not furnishing any yarn. Fluctuations in yarn
tension caused or allowed by the zero point calibration during this period
of time cannot cause any impairment of the knitted goods produced.
Alternatively, it is possible to perform the zero point calibration by
briefly lifting the yarn from the yarn feeler element when the yarn is
moving slowly or is not changing its speed of motion at the moment. In
that case, the regulating device that regulates the yarn feed is briefly
blocked; that is, its output signal is frozen at the current value, the
zero point calibration is performed, and the closed control loop is
re-activated once the yarn has been placed back on the yarn feeler
element.
For reliably detecting that the motor is stopped for a long enough time,
the motor trigger signal is monitored. If a pronounced transition of the
trigger signal from a value other than zero to the value of zero appears,
then it is assumed that the motor has been stopped intentionally. In
flatbed knitting machines, because of the special mode of operation after
an intentional stop of the feed wheel mechanism motor, restarting of the
engine can be expected at the earliest after a predetermined period of
time has elapsed; in this example approximately 500 ms. The same is true
upon a yarn change in stocking or sock knitting machines. Preferably, a
waiting period of 20 ms, for instance, is waited out, and if the trigger
signal after this waiting period has elapsed is still zero, then the
calibration operation is permitted. This operation lasts several tens of
milliseconds. The calibration operation is performed only when permitted
(enabled) and (as a second criterion) when required. As a rule, this is
done at regular time intervals. These intervals can be shorter (e.g.,
every two minutes) at first, after the machine is turned on, and then
longer (e.g., every 30 minutes) once the machine is up to its operating
speed.
The yarn tension sensor preferably has a drive mechanism, such as a tension
magnet or other kind of drive mechanism (electrical or pneumatic drive
mechanism of the rotary, pivoting or linear type) assigned to the yarn
takeup system. This mechanism can be activated by a calibration device and
drives the cam in such a way that the yarn takeup system is moved to its
first position in which the yarn is lifted from the yarn feeler element.
The zero point calibration can now be performed. Once the drive mechanism
is deactivated, the yarn takeup system assumes its second position, in
which the yarn rests on the yarn feeler element. Preferably, in this
position the yarn takeup system is separated from the yarn, or in other
words does not touch it. This eliminates measurement errors from friction
of the yarn against the yarn takeup system. However, it is also possible
to utilize the yarn takeup system intentionally for guiding the yarn. In
the first version described above, the yarn is in engagement with either
the yarn takeup system or the yarn feeler element. In the second variant,
the yarn is always in contact with the yarn takeup system, regardless of
whether it is lifted away from the yarn feeler element or not.
The yarn takeup system is formed by one and preferably two yarn receivers
adjacent to the yarn feeler element. In the simplest case, these are pegs
that extend parallel to the preferably also peglike yarn feeler element.
Eyelets can also be used. Both the peg of the yarn feeler element and the
pegs of the yarn takeup system extend crosswise to the yarn travel
direction, preferably at a right angle to it. As a result, it is attained
that even with relatively wide pegs, all the yarn positions on the peg are
of equal rank, so that the yarn does not dig in at any one point.
The yarn feeler element of the yarn tension sensor is preferably supported
on a spring parallelogram. The preferably peglike yarn feeler element is
then disposed at a right angle to the leaf springs. As a result, it
suffices to fasten and support the yarn feeler element on only one side,
and good dimensional accuracy is assured.
The measuring device preferably has two travel pickups, whose output
signals preferably vary inversely upon a deflection of the yarn feeler
element. This makes offset suppression in the evaluation circuit possible.
This circuit is preferably a subtractor circuit, which can be formed by a
bridge circuit, operational amplifier, or other suitable means.
The yarn tension sensor of the invention and the yarn feeder of the
invention are intended for use in a flatbed knitting machine, for
instance, in which the aforementioned calibration operation or zero point
calibration operation can be done for instance upon a reversal of
direction of the yarn guide or upon a yarn change. If the yarn guide is
moving away from the yarn feeder, for instance, and stops at the end of
its movement stroke in order to turn around, then the required yarn feed
quantity, regardless of the knitting pattern at the time, is briefly zero.
A separate calibration circuit can detect this and can activate the drive
mechanism briefly so that the yarn is lifted from the yarn feeler element
and the measured value that is then established is detectable as a zero
point. Once this has been done, the calibration circuit deactivates the
drive mechanism, so that the yarn is placed back on the yarn feeler
element. The entire operation can be completed within from several
milliseconds to several tens of milliseconds, given a suitable design of
the yarn tension sensor and of the drive mechanism for the yarn takeup
system. The stoppage time available at the change of direction of the yarn
guide is thus sufficient to perform the calibration.
It is also possible to perform the calibration at other occasions that
involve low yarn travel speed or a zero yarn travel speed. For instance,
the yarn feeder can be operated in a standby or stopped mode upon stoppage
of the knitting machine. If the yarn feeder is moved out of this state
(turned on), then the brief calibration operation can be performed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a yarn feeder with a yarn tension sensor with the sensor cover
removed, in a complete perspective view.
FIG. 2 shows the yarn feeder of FIG. 1 in a schematic side view.
FIG. 3 shows the yarn tension sensor of the yarn feeder of FIGS. 1 and 2 in
a simplified perspective view and on a different scale.
FIG. 4 shows the yarn tension sensor of FIG. 3 in a plan view.
FIG. 5 shows the yarn tension sensor of FIG. 4 in a schematic basic
illustration intended to explain its functional principle.
FIG. 6 shows the yarn tension sensor of FIG. 4 in a section taken along the
line VI--VI.
FIG. 7 shows the yarn tension sensor of FIG. 4 in a schematic front
elevation.
FIG. 8 shows the yarn tension sensor of FIG. 4 in a side view.
FIG. 9 shows an electrical circuit for signal processing of the output
signals of two Hall sensors acting as travel pickups.
FIG. 10 shows a flowchart to illustrate the method in the zero calibration
of the yarn tension sensor.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, a yarn feeder 1 is shown whose housing 2 has a substantially
flat front side 3. A yarn feed wheel 4 and a yarn tension sensor 5 are
disposed on it. The housing 2 of the yarn feeder, which is provided with
means not further shown for fastening to a knitting machine, in particular
a flatbed knitting machine, has next to the yarn feed wheel 4 an eyelet 6
for guiding a yarn 7, which is represented by merely a portion. The eyelet
6 is provided with a ceramic insert 8 and is disposed upstream of the yarn
feed wheel 4, with respect to the yarn travel direction represented by an
arrow 9. On the opposite end of the housing 2, a further eyelet 12 with a
ceramic insert 13a is disposed following a signal light 11.
In the yarn travel path 13 defined between the eyelets 6 and 12, the yarn
feed wheel 4 serves to feed and supply yarn 7 as needed, and the yarn
tension sensor 5 serves to monitor the yarn tension. A regulating device
disposed in the housing 2 correspondingly controls a motor that serves
drive the yarn feed wheel 4 on the basis of a signal furnished by the yarn
tension sensor.
The yarn feed wheel is preferably embodied with six or more vanes and has a
plurality of spokes 15, 16, extending radially away from a hub 14, which
are each joined together on the ends by a strut 17. One pair of spokes and
one strut 17 each define one vane 18. The vanes 18 are disposed at equal
angular intervals. The yarn feed wheel 4 therefore defines a polygonal
outer circumference, on which the yarn 7 rests in the form of a regular
hexagon.
The yarn feed wheel 4 is followed by the yarn tension sensor 5, which has a
peg 21 acting as a yarn feeler element. The peg extends crosswise to the
yarn 7, which runs in an obtuse angle over the outer circumferential
surface of the cylindrical peg 21. As FIG. 2 shows, the yarn feed wheel 4
is rotatable about a pivot axis 22, which is not parallel to a
longitudinal axis 23 defined by the peg 21. Advantageous conditions for
the yarn on leaving the yarn feed wheel 4 are achieved by means of the
oblique position of the yarn feed wheel 4 relative to the peg 21 and thus
the yarn 7. The yarn is paid out at a larger angle. This brings about an
exact release of the yarn from the yarn feed wheel or other windings taken
up by the yarn feed wheel. To the extent that the yarn payout conditions
are independent of the orientation of the peg 21, the yarn 7 leads away at
an acute angle to an imaginary plane 24 (FIG. 2) for which the pivot axis
22 defines the normal direction. This is achieved by suitable positioning
of the eyelet 12.
The yarn tension sensor 5 can be understood particularly from FIGS. 3-5.
The peg 21 is supported on its end on a carrier 27 of low mass, which is
held, movable substantially in the longitudinal direction, by two leaf
springs 28, 29 disposed in the manner of a spring parallelogram. On the
end, the carrier 27 protrudes with cylindrical portions into damper pots
or tubules 31, 32, which contain a more or less viscous fluid. By this
means, a suppression of high-frequency signal components, in particular,
is attained, components that can for instance occur because of the
polygonal outline of the yarn feed wheel 4.
The leaf springs 28, 29 are retained on their ends on suitable receptacles
33, 34 which are secured to a base 35. As can be seen from FIG. 7, the
base is disposed in stationary fashion with a total of four damper
elements 36, which are preferably of rubber. The base 35, as seen from
FIG. 4, is formed for instance by a U-shaped yoke 35a. A permanent magnet
37 is disposed on the carrier 27, and its magnetic field reaches and
influences two Hall sensors 38, 39 disposed in the immediate vicinity.
Even a slight shift in the location of the carrier 27 relative to the base
35 is detected by the Hall sensors 38, 39.
The yarn tension sensor 5 includes a calibration device with two pegs 42,
43, acting as yarn takeup systems 41, which are disposed substantially
parallel to the peg 21. The pegs 42, 43 are retained on a carrier frame
44, which is movable with the pegs 42, 43 crosswise to the peg 21 in the
direction of the arrow 45 (FIGS. 3, 4 and 5). The yarn takeup system 41
can thereby be moved to at least two different positions. In a first
position, shown in dashed lines in FIG. 5, the pegs 42, 43 are in a
location in which they lift the yarn 7 from the peg 21. In this position,
no forces originating in the yarn 7 act on the peg 21.
In a second position of the yarn takeup system 41, which is shown in heavy
lines in FIG. 5, the yarn 7 rests only on the peg 21, but not on the pegs
42, 43 of the yarn takeup system 41. The yarn tension now causes a
corresponding deflection of the peg 21 and thus results in a sensor output
signal.
The yarn takeup system 41 is connected to a drive mechanism 46. To that
end, the pegs 42, 43 are held by a frame 47 that surrounds a magnet coil
drive 48. Its magnet coil 49 has an armature 51 connected to the frame 47.
The frame 47 is supported displaceably in the adjustment direction (arrow
45) by suitable guide means 52, such as oblong slots 54 provided in a base
plate 53, or the armature 51.
To prestress the yarn takeup system 41 toward its second, inactive
position, the frame is connected to the base plate 53 via a spring means
56. The spring means 56 is preferably a leaf spring 57, which is retained
on one end on the base plate 53 and with its opposite end is joined to the
frame 47.
The Hall sensors 38, 39, shown only schematically in FIG. 5, are connected
as shown in FIG. 9 to a measurement circuit 61, which processes output
signals present at outputs 62, 63 of the Hall sensors 38, 39. The Hall
sensors 38, 39 are disposed such that they output contrary signals. If the
carrier 27 is deflected in one direction, the signal of the Hall sensor 38
increases, for instance, while that of the Hall sensor 39 decreases. For
evaluating these signals, the measurement circuit 61 is embodied as a
subtractor circuit and to that end includes an operational amplifier 65.
This element acts as a differential amplifier. The voltage gains at the
noninverting and inverting inputs are identical in amount to one another
but differ in their sign. This is assured by suitable wiring.
In addition, the amplifier is preceded by low-pass filters TP1 and TP2, for
suppressing higher-frequency components of the sensor signals. At the
output, a value for the difference of the output signals of the Hall
sensors 38, 39 is thus present that is averaged over time and amplified.
Because of the polygonal outline of the yarn feed wheel 4 and the direct
guidance of the yarn to the peg 21 without an intervening bearing surface,
the yarn 7 periodically changes its angle to the peg 21. Fluctuations in
the sensor signal caused thereby are filtered out by the low-pass
characteristic of the measurement circuit 61.
A change in the installed position of the yarn feeder 1, or deposits on the
peg 21 and on the mounts of the magnet 37, or changes in the temperature
or drift phenomena in the Hall sensors 38, 39 and temperature drift or
aging of the measurement circuit 61 can gradually lead to a change in the
output signal at the output of the measurement circuit 61. To detect a
zero point shift of this kind, the yarn feeder 1 is provided with an
automatic calibration or zero point calibration circuit. This circuit is
connected to the magnet coil 49.
The yarn feeder 1 carries out its calibration as follows:
First, it is assumed that a knitting machine provided with the yarn feeder
1 and not otherwise shown is not in operation. The yarn feeder 1 is turned
off, but its electronic circuit is active. It is in a waiting state. To
put the knitting machine into operation, among other steps, the yarn
feeder 1 is also activated. The calibration circuit to that end briefly
triggers the magnet coil 49, which attracts the armature 51. This pushes
the frame 47 so far toward the peg 21 that the pegs 42, 43 bypass the peg
21 and lift the yarn 7 away from the peg 21. The peg 21 is now free of
yarn forces, and the signal output by the measurement circuit 61 in this
state marks the zero point, or in other words the yarn tension of zero.
As soon as this value is detected and recorded, the excitation of the
magnet coil 49 is turned off, so that the armature 51 drops, and the frame
47 is returned by the spring means 56 to its retracted position. The yarn
7 is placed on the peg 21 in the process, and the pegs 42, 43 release the
yarn 7. The force now exerted by the yarn 7 on the peg 21 causes a shift
in the carrier 27, which is detected by the Hall sensors 38, 39 and
indicated as an output signal by the measurement circuit 61. This signal
serves as an actual value signal for a closed control loop that controls
the motor of the yarn feed wheel 4.
If yarn consumption then occurs, the closed control loop triggers the motor
in each case in such a way that the yarn feed wheel 4 furnishes the
required quantity of yarn to keep the yarn tension constant.
The prevention of errors from zero point drifting that occurs after the
yarn feeder is put into operation can be accomplished by repeating the
described calibration operation often. This is possible in particular in
time slots in which, during the operation of the yarn feeder 1, the yarn
feed wheel 4 and thus the yarn 7 come to a stop. This state is
characterized for instance by a corresponding controller output signal
(motor trigger voltage equal to zero). To detect such time slots, the
calibration circuit monitors the controller output signal. If such a time
slot is occurring, then the calibration operation, which takes only a few
milliseconds or a few tens of milliseconds, is tripped; that is, the
magnet coil 49 is briefly excited, and the zero calibration of the
measurement circuit 61 is formed taking the resultant output signal as the
zero value.
To detect possible time slots, there is first a wait time period, as shown
in the flowchart of FIG. 10, until an internal time t.sub.abgl., which can
be preset, has elapsed. The time t.sub.abgl. is the time interval within
which a zero calibration should be performed. It ranges between a few
minutes and one hour. Once the interval time has elapsed, the controller
output signal is first examined for whether it is tending toward zero.
After that, a check is made as to whether it remains at zero for a given
length of time, such as 20 ms. If so, then a time slot is occurring, and a
wait ensues until the motor of the yarn feeder mechanism has been
intentionally stopped and remains stopped for a relatively long time (500
ms). During such a time slot, the calibration can be performed. The
detection of the time slots is preferably done in an edge-triggered way.
In a machine where the yarn consumption intermittently stops, an automatic
calibration can be done at the carriage or yarn guide reversal, which
occurs when the motor of the yarn feed wheel 4 stops. Once such a motor
stop is detected, then after a predetermined variable length of time an
automatic calibration can be performed. In this way, it is possible for
even brief and relatively rapidly ensuing drifting within the entire
system to be detected and rendered harmless.
A yarn feeder 1 intended in particular for machines in which yarn
consumption is intermittently absent and with elastic yarns has a yarn
tension sensor 5 which is provided with a calibration device 40. The
calibration device lifts the yarn 7 from a peg 21, belonging to the yarn
tension sensor 5, at times when this can be done without impairing the
operation of the yarn feeder 1. Such times are preferably time slots when
no yarn feeding is necessary. Once the yarn 7 is lifted from the peg 21, a
zero point calibration is performed, so that zero point drifting in the
entire sensor system, including its measurement circuit 61, is detected
and can be compensated for.
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